Two-piece clockspring with lock and wire harness assembly

ABSTRACT

A clockspring interconnector comprising a housing defining a chamber and a rotor cover attached to the housing. A coiled flat cable carried within the chamber surrounding the rotor cover. The flat cable having a first end attached to a first connector location of the rotor cover and a second end attached to a second connector location of the housing. The rotor cover includes an inner wall defining a central aperture having a top opening and a bottom opening. The inner wall having integral flanges extending from the rotor cover adjacent to the bottom opening. The housing having a center hole having a rim at its external diameter. The rotor cover snap fits to the housing via the flanges having angled surfaces to slide past the rim and a protruding surface to engage the rim of the housing. The first and second end of the flat cable including a backbone to receive the end of the flat cable. A backbone protrudes from the rotor cover at a first connection location and a second connection location. The backbone including parallel channels for positioning the conductors of the flat cable. Conductors welded to uninsulated end portions of external wires and secured by a backbone cover having a strain relief means. An automatic unlocking means included in the rotor cover. The unlocking means includes a depressed or unlocked position and an undepressed or locked position. Upon assembly of the clockspring onto a steering column, the unlocking means is depressed disengaging a detente of the locking means from the recess of the housing allowing the rotor top to rotate. Further, an externally exposed locking means limits rotation of the rotor cover to 350° and may be permanently removed after assembly of the clockspring to a steering assembly. In addition, a nonreplaceable lock is provided for limiting rotation to approximately 180° during final assembly of the clockspring to a steering assembly and providing a means for prohibiting replacement of the lock after removal.

This application is a continuation-in-part of U.S. Ser. No. 08/196,311,filed Feb. 14, 1994.

BACKGROUND OF THE INVENTION

This invention pertains to a clockspring interconnector for enclosing anelectrical conductor cable, the clockspring interconnector electricallyconnecting a rotatable electric device with a stationary electricdevice.

An increasing number of automobiles have air bag crash systems. An airbag is typically located on the steering wheel facing the driver. Theair bag must be in continuous electrical connection with sensors in thecar body. The sensors provide an electrical signal to the air bag crashassembly which instantly inflates the air bag in the event of a crash.

Accordingly, them is a need for an electrical connection between therotatable portion of the air bag assembly which is mounted to thesteering wheel, and the remaining portion of the assembly, which is in astationary position in the car body. Electrical connections betweenrotatable and stationary pans are well known. Typically, an electricalbrush rests upon a conductive ring, with one of the pans being rotatableto provide such rotatable electrical connection. However, there is arisk, particularly during the impact of an accident, of a transientfailure of electrical connection with a brush and ring system, whichwould result in failure of the entire air bag system crash assembly.

Accordingly, a clockspring interconnector has been previously developed,comprising an outer housing, a rotor member and multiple intermediatehousing members for enclosing and connecting the members; the housingand rotor member rotatably associated with one another at a plurality ofbearing surfaces. A "clockspring" is located inside the interconnector.The clockspring is a flat conductor cable and has two ends conductivelyattached to conductor wires which pass out of the interconnector tounite the air bag to the sensing device. The interconnector is mountedon the steering column, and the steering wheel may be rotated in eitherdirection while a continuous, positive electrical connection is providedbetween air bag sensors via the clockspring interconnector.

While prior an clockspring interconnectors are effective to provide thenecessary continuous electrical connection between an air bag or otherdevice on a rotating column and a stationary portion of a circuit, theprior an systems were sometimes wound completely tight before the devicewas installed making the installed device useless. This problem waspartially solved by providing a clockspring assembly with a device thatkept the clockspring interconnector from rotating prior to installation.

Such a locking mechanism was described in U.S. Pat. No. 4,722,690. Thatpatent describes a clockspring interconnector which includes aprojection which engages a noncircular aperture of the rotor member toprevent the rotor member from rotating. This projection was removable byhand by reaching into the center aperture of the clockspring. Thisdesign is disadvantageous in that it requires a center aperture which isnoncircular and also requires exposure of the center aperture on theclockspring so that an operator may grasp the projection for removal. Incertain assembly operations of the clockspring to the steering wheel andsteering column, it is sometimes impossible to remove such a lockingprojection which may become enclosed by a steering wheel housing orsteering column housing. Thus, there is a need for a removable externallocking means which may be exposed after assembly of the clockspringwith a steering wheel housing and steering column housing. Such priorart locking mechanisms also required an additional locking mechanism tolock the steering column assembly prior to assembly of the clockspringassembly. Such an improved external locking means providing exposureafter assembly could also eliminate the extra part for the steeringcolumn locking mechanism.

U.S. Pat. No. 5,171,157, describes a clockspring interconnectorincluding spring-loaded locking pegs integral to the internal hub of therotor. This patent describes locking pegs which may be depressed onlyupon engagement from above, providing direct vertical force onto thelocking pegs. Such a design requires that a column being insertedthrough the center of such a clockspring have protruding portions whichwill project perpendicular to the path of insertion of the column intothe clockspring and provide surfaces which will engage the locking pegsin a vertical direction. Such a system is disadvantageous because thehub being inserted into such a clockspring must be specially designed sothat the protruding portions of the hub engage the locking pegs whilestill allowing complete mating insertion of the column through theclockspring and with the steering assembly. Accordingly, it is desiredto have a locking means which may be engaged without the need of aspecially design column.

U.S. Pat. No. 5,059,134, describes a connection location where theelectrical conductors of the flat ribbon cable are serially connected toa connection conductor wires via the engagement of the uninsulated endportions of conductor wires against a clamping body which is surroundedby a protective sheath injection molded about the clamping body. Thisarrangement is both difficult and costly to assemble. In order toposition the clamping body against the conductor wires and theninjection mold the protective sheath about the clamping body, requiresthat this operation be done separately from the assembly of the flatcable within the clockspring housing. Accordingly, an improved structureis desired which allows for the simple, inexpensive and quick attachmentof external conductor wires to the electrical conductors of the flatcable so that all assembly of the clockspring may occur prior to theattachment of the external cables.

Generally, clocksprings have been known to have been assembled having atleast three components. U.S. Pat. No. 4,607,898, describes a clockspringhaving a first half and a second half which is a assembled by a faceplate. The assembly of the clockspring having three or more pans isdisadvantageous due to the need to manufacture and then assemble themultiple parts which is costly and time-consuming and the increasednumber of bearing surfaces which create noise. Accordingly, there isdesired a clockspring which has only two parts and a single bearingsurface and may be assembled together quickly and easily. Such anassembly including all of the above described advantages is possible byincorporating the structures of the present invention either in a singleclockspring assembly or as individual components of separate clockspringassemblies.

It is an object of the present invention to overcome all of thedisadvantages of the prior art clocksprings by incorporating aclockspring structure which provides a design which is quickly andinexpensively assembled.

It is another object of the present invention to provide a clockspringassembly which is immobile until it is attached to a standard steeringcolumn.

It is a further object of this invention to provide a clockspringassembly that becomes immobile once it is disengaged from a standardsteering column shaft.

It is yet another object of this invention to provide a clockspringassembly which remains immobile after assembly to a steering column butafter adjustments to the steering column are made and withoutdisassembling the clockspring from within a steering housing andsteering wheel, the clockspring may be mobilized.

It is a further object of the present invention to provide a two-piececlockspring which may be assembled quickly and easily.

It is another object of the present invention to provide a clockspringstructure which allows for the complete assembly of the clockspringprior to attachment of external cables.

It is yet another object of the present invention to provide for aclockspring assembly which allows for the quick and easy attachment ofexternal cables at the conclusion of the assembly of the clockspringitself.

SUMMARY OF THE INVENTION

The above objects and advantages are provided by a clockspringinterconnector comprising a housing defining a chamber extendingtherethrough and a rotor cover attached to the housing. A coiled flatcable carried within the chamber surrounding the rotor cover. The flatcable having a first end attached to a first connector location of therotor cover and a second end attached to a second connector location ofthe housing.

The rotor cover defines a central aperture having a top opening and abottom opening. The external diameter of the aperture having integralflanges extending from the rotor cover adjacent to the bottom opening.The housing having a center hole having a rim at its external diameter.The flanges having angled surfaces to slide past the rim and aprotruding surface to engage the rim of the housing and secure the rotorcover thereto.

The first and second end of the flat cable including a backbone toreceive the end of the flat cable. The backbone protrudes from the rotorcover at a first connection location. The backbone protrudes from thehousing at a second connection location. The backbone including parallelchannels for positioning the conductors of the flat cable. The channelsof the backbone are separated by fibs and positioning ribs. The ribs areadjacent to the conductors of the flat ribbon cable. The positioningribs receive insulated wires having uninsulated end portions. Thepositioning ribs engaging the wires at an insulated portion. The wiresbeing press fit between the positioning ribs and aligned with theconductors of the flat cable. The positioning ribs are heat stakedsufficiently to deform the positioning ribs to trap the wire within thechannels. The uninsulated end portion of the wire is welded to theconductors of the flat cable. A backbone cover is attached to thebackbone. The backbone includes a gap running transverse to thechannels. The backbone cover includes a rib. Upon attachment of thebackbone cover to the backbone having the insulated wire insertedtherein, the rib engages the insulated portion of the wire, pushing thewire into the gap. The backbone cover is secured to the backbone byplacement of a rivet through the backbone cover and the backbone.

An automatic unlocking means is included in the rotor cover. Theunlocking means includes a depressed or unlocked position and anundepressed or locked position. The locking device includes acompression spring which urges the locking assembly having a detente toengage a recess along the rim of the housing. Upon assembly of theclockspring onto a steering column, the unlocking means is depressed,disengaging the detente of the locking means from the recess of thehousing allowing the rotor cover to rotate.

A locking means is provided having a latching body seated within achannel of the housing. A stop head protrudes from the latching body.The stop head engages a stop wing of the rotor top. The stop wingincludes a neck portion. A narrow neck portion of the stop wing allowsfor rotation of the rotor cover in 350° and upon abutment of the stophead against the neck portion of the stop wing, the rotor cover isprohibited from making a full rotation. A pull tab is connected to thelatching body and protrudes perpendicular to the sidewall of thehousing. The pull tab includes an arm of sufficient length to allow forthe pull tab to protrude sufficiently to be gripped subsequent to theassembly of the clockspring within a steering wheel housing and steeringcolumn housing. Pulling on the pull tab with sufficient force disengagesthe latching body from the channel of the housing and removes the stophead from its position, allowing the free rotation of the stop wing androtor cover.

A further embodiment of the present invention includes a nonreplaceablelocking means preventing the rotation of the rotor cover more than 180°.The nonreplaceable locking means having a securement tab which remainswithin a slot of the clockspring after removal of the nonreplaceablelocking means. The nonreplaceable locking means attached to the rotorcover. The clockspring interconnector comprising a lip protruding fromthe housing. A projection protruding from the housing a specifieddistance from the lip. A stop tab attached to the nonreplaceable lockingmeans which will abut the lip when rotated in a first direction and theprojection when rotated in a second direction. The clockspringinterconnector includes a gripping member attached to the nonreplaceablelocking means. The gripping member, the stop tab and the securement tabare integrally connected. The securement tab includes a means forseparation of the securement tab from the nonreplaceable locking means.The means for separating the securement tab includes a bite for allowingthe ripping separation of the nonreplaceable locking means from thesecurement tab. Removal of the nonreplaceable locking means allows therotor cover to rotate more than 180°.

These and other features of the invention are set forth below in thefollowing detailed description of the presently preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a clockspring;

FIG. 2 is a side view of FIG. 1;

FIG. 3 is a top view of FIG. 1;

FIG. 4 is a cut-away, side elevation view of FIG. 3 taken at line A--A;

FIG. 5 is a bottom view of FIG. 1;

FIG. 6 is a cut-away, side elevation view of FIG. 5 taken at line B--B;

FIG. 7 is an end view of a backbone cover;

FIG. 8 is a side elevation view of a backbone cover;

FIG. 9 is a top view of a backbone;

FIG. 10 is an end view of an assembled backbone;

FIG. 11 is an enlarged top view of an assembled backbone;

FIG. 12 is a cut-away, side elevation of FIG. 3 taken at line D--D;

FIG. 13 is a cut-away, side elevation view of FIG. 3 taken at line C--C;

FIG. 14 is a cut-away, side elevation cut-away view of FIG. 3 taken atline C--C;

FIG. 15 is a top view of an alternative embodiment of a clockspring; and

FIG. 16 is an enlarged cut-away side elevation view of FIG. 15 taken atline E--E.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

The clockspring interconnector of this invention is better understood byreferences to FIGS. 1-14 which shows various aspects of a presentlypreferred clockspring interconnector. Turning to FIG. 1, the clockspring10 includes a housing 12 having a sidewall 14. Enclosing the top of thehousing 12 is the rotor cover 16. The rotor cover 16 combines theseparate prior art components of a rotor and a cover into a singleintegral component. The rotor cover 16 includes flanges (not shown)which allow the rotor cover 16 to snap-fit onto the housing 12. Thus,the main components of the clockspring 10 are only the rotor cover andthe housing 12. There are no other members needed to enclose the chamber18 of the housing 12 and no other parts needed to hold the clockspring10 together. This two-piece design minimizes costs by having only thetwo parts and the two components are quickly and easily assembled,saving in labor, storage and tooling costs. The unique design alsoincludes a single bearing surface at the attachment means of the flangesbecause the top 17 of the rotor cover 16 is separated from the housing12 by a gap 15 and does not bear together in this area.

The rotor cover 16 includes an aperture 20 having a top opening 21 and abottom opening 22. The aperture includes an inner wall 24. Along thecircumference of the inner wall 24 of the rotor cover 16 resides anautomatic unlocking means 30 to provide for the unlocking of the rotorcover 16 allowing it to rotate freely on the housing 12. The automaticunlocking means 30 includes a button 35 having a sliding surface 31 andis received in cell 32. The button 35 is shown in its undepressed,locked position prior to assembly of the clockspring 10 to a steeringassembly. Upon assembly to a steering assembly and insertion of sectionof steering wheel through aperture 20 of the rotor cover 16, thesteering wheel will engage sliding surface 31 and force the button 35 tomove in the direction of arrow 33, transverse to the direction ofinsertion of the steering wheel. Movement of the button 35 in directionof arrow 33 causes the button 35 to recede into the cell 32 causing thefront surface 34 to become flush with the inner wall 24 of aperture 20.The movement of the button 35 in direction of arrow 33 also causes adetente (not shown) of button 35 to disengage from a recess of thehousing 12 and allow for the rotor cover 16 to rotate freely from thehousing 12.

This arrangement of the automatic unlocking means 30 allows for theshipping of the clockspring while it is in its locked position andprohibits the flat cable in the chamber 18 of the housing 12 fromunwinding during shipping and causing the disalignment of the rotorcover 16 from the housing 12. In the assembled state of the clockspringwith a steering mechanism, it is essential that the clockspring have atleast two and a half turns in each direction. Thus, it is necessary thatwhen the clockspring is assembled to the steering mechanism that it becentered. This ensures that there be enough turns necessary for theproper functioning of the clockspring. Failure to provide the assemblyof a properly centered clockspring may cause the locking of the rotorcover or rupture of the flat cable of the clockspring when turned toofar in one direction. In a preferred embodiment, the unlocking means 30slidably engages and disengages in a direction transverse to thedirection of the insertion of the steering wheel assembly. The unlockingmeans 30 also allows for the removal of the clockspring from thesteering assembly for repairs while prohibiting the unwinding oruncentering of the rotor cover 16 in relation to the housing 12. Thus arepair worker may simply remove the clockspring 10 from the steeringassembly which will cause the button 35 to disengage from cell 32 andits detente will engage the recess of the housing 12. This automaticunlocking means 30 ensures the rotor cover 16 is centered on the housing12 at all times when the clockspring 10 is disassembled.

While the automatic unlocking means 30 provides for a means ofpreventing rotation throughout the life of the clockspring, a moretemporary mechanism is the locking means 40. This locking means 40 mustbe manually removed and provides for locking of the clockspring 10 evenafter assembly to a steering assembly, when the unlocking means 30 isdepressed and unlocked. However, this locking means 40 will be discussedin a separate context from the automatic unlocking means 30 in that itwill be assumed that they will function independently of the otherunless stated otherwise. The locking means 40 includes a latching body41 which is seated within a channel 42 which is formed along the outerwall 14 of the housing 12. The locking means 40 is seated within thechannel 42 by frictional engagement of a base portion 43 of the latchingbody to engage a sill 44 of the channel 42. Integral with the latchingbody 41 is a stop head 45 which protrudes above the plane of the rotorcover 16. The stop head 45 is oriented to engage a stop wing 48 integralwith the rotor cover 16. The stop wing 48 includes a neck portion 49.Upon rotation of the rotor cover 16 in a counterclockwise direction, theneck portion 49 of the stop wing 48 will abut the stop head 45 of thelocking means 40. The rotor cover 16 may also be rotated in theclockwise direction. However, the rotor cover 16 will be prohibited frommaking a full rotation in that the neck portion 49 of the stop wing 48will abut the other side of the stop head 45 and inhibit furtherrotation. In a preferred embodiment of the invention, the neck portion49 is sufficiently wide so that rotation is limited to 350°. Theenlargement of the widths of the neck portion 49 decreases the amount ofrotation that is allowed by the rotor cover 16. Inversely, thedecreasing of neck portion 49 of the stop wing 48 will increase thedegree of rotation that is allowed by the rotor cover 16. For example,another embodiment of this invention could provide a neck portion 49which protrudes around 180° of the rotor cover 16. Thus, the rotor coverwould only be allowed to rotate 180° before abutting the neck portion 49of stop wing 48.

The amount of rotation necessary depends upon the assembly proceduresrequired. In a preferred embodiment, the clockspring 10 is assembledonto a steering assembly in which the rotor cover 16 is enclosed in asteering wheel housing and the lower portion of the housing 12 isenclosed in a steering column housing. However, even after assembly ofthe clockspring 10 to a steering assembly, further assembly is requiredin some circumstances of the steering column to the drive mechanism.This assembly may require rotation of the steering column and in turn,the steering wheel assembly. In order to assemble a number of parts ofthe steering column, large degrees of rotation may be required for theeasy assembly thereof. However, during this assembly, it is stillessential that the clockspring remain centered. During such assembly ofthe steering column, it is possible that without a proper lockingmechanism that the clockspring will become uncentered and be turned toofar in one direction so that when the steering column mechanism isfinally and completely attached, the clockspring will be out ofalignment. As well, if the clockspring 10 includes an automaticunlocking means 30, as discussed above, the assembly of the clockspringwill unlock the automatic locking means and allow full rotation of therotor cover 16 upon the housing 12. In such a case, upon conclusion ofthe assembly and at operation of the steering wheel, it is likely that aturn in one direction will break the flat cable, while turning in theother direction would allow rotation well beyond two and a half turns.Thus, the engagement of a the stop head 45 against the neck portion 49of the stop wing 48 while prohibiting rotation of the rotor cover 16beyond 360°, does allow for limited motion of the clockspring andsteering assembly to which it is attached for the proper assembly of thesteering column. Following such assembly and returning of the steeringwheel to its centered position, the locking means 40 may then beremoved. The above advantages are realized for the locking means 40 of aclockspring having both a locking means 40 and an automatic unlockingmeans 30 only where the steering mechanism is assembled after theclockspring is assembled to the steering column.

Pull tab 46 is provided which protrudes perpendicular from the side wall14 of the housing 12. The pull tab 46 is positioned vertically on theside wall 14 so that it protrudes from a gap which exists when asteering wheel housing is assembled above it and a steering columnhousing is assembled below it. The length of the arm 47 of the pull tab46 is dependent upon the overhang that the steering wheel housing andthe steering column housing protrude from the clockspring 10. The pulltab 46 includes gripping portion 78 which allows for easy pulling of thepull tab 46 and removal of the locking means 40 from the channel 42.While finger 49 maintains the latching body 41 of the locking means 40within the channel 42, upon pulling on the pull tab 46, the base portion43 of the latching body will ride over the finger 49 and allow removalfrom the channel 42. Upon pulling of the pull tab 46, the stop head 45will slide down the side wall 14 of the housing and follow the pull tabout and from between the gap created between the steering wheel housingand the steering column housing. Having removed the locking means 40,the clockspring 10 will be able to rotate freely. Once the locking means40 is disengaged, it cannot be replaced within channel 42 and onlyprovides a temporary locking feature.

The housing 12 defines chamber 18 which houses the flat cable. The flatcable is wound around the inner wall 24 of the rotor cover 16. The flatcable has a first end and a second end. In a preferred embodiment, thefirst end is connected to the rotor cover 16 at a first connectionlocation 50. The first connection location 50 includes a backbone 51which is inserted through passage 58 and protrudes beyond the topsurface of the rotor cover 16. The first connection location 50 securesthe conductors of the flat cable in an accessible orientation on thebackbone 51. Upon complete assembly of the clockspring 10, externalcables 60,61 may be attached quickly and easily to the backbone 51. Theexternal cables 60,61 may attach to controls in the steering wheel or toa squibb connector 62 which connects to an igniter which activates theair bag. The second end of the flat cable is terminated at a secondconnection location 55 having a similar construction to the firstconnection location and having external wires 63 attached thereto whichmay attach to a sensing device or power source within the enginecompartment of an automobile.

Turning to FIG. 2, a side elevation of the clockspring 10 of FIG. 1 isshown. The top rotor cover 16 is shown attached to the housing 12. Itcan be seen that there is a gap 15 which is present between the housing12 and the rotor cover 16. Assembly of the clockspring 10 having the gap15 allows for rotation of the rotor cover 16 on the housing 12 withouthaving a surface for rubbing which may cause excessive noise orfriction. The gap 15 reduces greatly the amount of bearing surfaces andprovides for a much easier rotation of the clockspring 10. Firstconnection location 50 is shown having backbone 51 enclosed by backbonecover 52 and having wires 53 leaving therefrom. A lip 54 is shown whichis formed integral with the rotor cover 16 and provides for a surfacefor the backbone cover 52 to slide into for securement around thebackbone 51. Locking means 40 is shown having latching body 41 and stophead 45. Second connection location 55 is shown where the second end ofthe flat cable is terminated. Integrally formed with the housing 12 aresnap legs 11 which provide for the snap mounting of the housing to asteering column housing. Locator pegs 13 also help mount the housing 12to a steering column housing.

Turning to FIG. 3, a top view of a clockspring 10 is shown. Rotor cover16 includes aperture 20. The rotor cover 16 has formed thereon the firstconnection location 50 and the automatic unlocking means 30. Lockingmeans 40 is shown attached to housing 12. The stop wing 48 is integrallyformed with the rotor cover 16 to engage stop head 45.

Turning to FIG. 4 a cut-away, side elevation view of FIG. 3 taken atline A--A is shown. In a preferred embodiment, rotor cover 16 isassembled directly to the housing 12. The housing defines a chamber 18in which the flat cable (not shown) is housed. The rotor cover 16 formsan aperture 20. The aperture 20 includes a top opening 21 and a bottomopening 22. The rotor cover 16 includes a top 17 and integral thereto aninner wall 24. The inner wall 24 at its exterior surface defines theaperture 20 and on its interior surface provides the rotor which theclockspring is wound about. Integral to the inner wall 24 are flanges25.

The housing 12 includes a center hole 26 into which the inner wall 24and aperture 20 of the rotor cover 16 is inserted. Protruding from thecenter hole 26 of the housing 12 is a rim 27. The engagement of theflanges 25 of the rotor cover 16 with the rim 27 of the housing 12provides for, the attachment of the rotor cover to the housing 12. Theflanges 25 include angled surfaces 28 and protruding surfaces 29. Therotor cover 16 is formed of a polymer material which is hard butflexible. Upon insertion of the flanges into center hole 26 of thehousing, the angled surface 28 of the flanges 25 of the rotor cover 16abut the upper surface of the rim 27. The flanges are stressed inwardlyand slide past the rim 27. Upon full insertion of the flanges into thecenter hole of the housing 12, the flanges snap outwardly engagingprotruding surface 29 under rim 27. In a preferred embodiment, eightflanges are present around the bottom opening 22 of the rotor cover 16providing engagement points at each 45° position around the rim 27 ofthe housing 12. Such an assembly provides for the permanent connectingof the rotor cover 16 to the housing 12 and also allows for the smoothrotation of the rotor cover 16 on the housing 12. However, as few asfour flanges may provide such functions as well. Shoulders 31 of therotor cover 16 provide for a tight fit and eliminate any wobbling uponmating of the rotor cover 16 with the housing 12. The shoulder 31 of therotor cover 16 and rim 27 of the housing 12 are the only bearingsurfaces of the present invention providing for low noise upon rotationof the rotor cover 16 against the housing 12.

Within the chamber 18 of the housing 12 are included insulating material70. This insulating material 70 provides for a surface of the flat cableto rub against. Upon rotation of the rotor cover 16 and movement of theflat cable, the rubbing and noise created by the rotation of the flatcable will be reduced. In a preferred embodiment, the insulatingmaterial is a mat fished vinyl foam tape (Great lakes Tape & Label,Inc.) having a cellular, flexible polyvinyl chloride (CH₂ --CHCL)_(n)foam composition. The vinyl foam tape includes an acrylic adhesive onone side so that it may easily be attached to the housing. Suchinsulation may also be attached to the underside 71 of the rotor cover16. The sound dampening that the insulating material provides is partlydue to the rough surface of the insulating material 70 which the flatcable rubs against. Also, first connection location 50 and secondconnection location 55 are shown.

FIG. 5 discloses a bottom view of the clockspring of FIG. 1. Housing 12is shown having center hole 26. The bottom opening 22 of the aperture 20of the rotor cover having integral flanges 25 snapped over the rim 27 ofthe housing 12. Second connection location 55 is shown.

Turning to FIG. 6, a cut-away, side elevation view of the secondconnection location taken at line B--B of FIG. 5 is shown. FIGS. 6-11all show a preferred embodiment of a wire harness connector whichterminates the end of the flat ribbon cable and allows for easy andquick attachment of external cables at the connection locations. Thediscussion of FIGS. 6-11 and the second connection location 55 alsoequally apply to the structure of the first connection location 50 andsuch structure can be interchanged at both locations. Second connectionlocation 55 is located at the base of housing 12 adjacent to sidewall14. The top 17 of rotor cover 16 is shown above the housing 12. Thehousing 12 forms a chamber 18 in which the flat conductor cable is woundaround the inner wall of the rotor cover 16. The flat cable includes afirst end terminating at the first connection location at the rotorcover and a second end terminating at the second connection location atthe housing 12.

The second connection location 55 consists of a backbone 51. In apreferred embodiment, the backbone 51 includes a first side 63 and asecond side 64. The second end portion of the flat ribbon cable 65 isreceived at the first side 63 of the backbone 51. The end portion 65 ofthe flat ribbon cable approaches the backbone 51 from a transversedirection. It meets the backbone 51 at the first side 63 and is thenfolded around the backbone 51 onto the second side 64 of the backbone51. The flat cable 56 is then folded down at an angle to form a changein the longitudinal direction of the flat cable 56 of approximately 90°so that the end portion 56 of the flat cable is travelling parallel tothe direction of the backbone 51.

Extending from the end portion 56 of the flat ribbon cable areelectrical conductors 57 which are uninsulated and extend from the latexcoating of the end portion of the flat cable 56. The conductors 57 arecarried within channels of the backbone 51. The backbone includes pinsto retain and hold the flat cable in place. The steps of securement ofthe flat ribbon cable to the backbone in order to terminate the flatribbon cable are all that occur during the assembly of the clockspring10. The simple and quick procedure of terminating the flat cable to thebackbone as described above and inserting the backbone into the passage58 of the housing are all the assembly required. The further assembly ofthe clockspring may occur without having to attach exterior cables tothe clockspring. Thus, the clockspring 10 may be handled easily andquickly without having the excess and cumbersome external wires andharnesses inhibiting the quick handling of the clockspring 10 on anassembly line. As the harness assembly is also a complicated and timelyprocess, it is helpful to be able to complete such an assembly separatefrom the clockspring and also have the advantages of completing theseassemblies without having the clockspring attached thereto, causing thecumbersome and timely handling. Simply by terminating the flat cable tothe backbone 51 and having the backbone protrude from the housingexposing the conductors 57 for future attachment of exterior cables is agreat cost saving measure.

Upon complete assembly of the clockspring 10 and assembly of the rotorcover 16 to the housing 12, the exterior cables may then be attached.The exposed conductors 57 of the flat cable are attached quickly andeasily to external cables by feeding the insulated wires 53 into thechannels of the backbone 51. Ribs between the channels guide theinsulated portions of the wires 53 into the channels. The uninsulatedwires 62 are placed adjacent to the conductors 57. The wires 53 are thensecured to the backbone 51 and the uninsulated wires 62 are soldered tothe conductor 57 as will be described in more detail below. A backbonecover 52 is attached to the backbone 51 to protect the terminatedconductor and attached wires 53. The backbone cover 52 also includes arib 66 which engages the insulated wires 53 at point 81. The rib 66forces the insulated wires 53 into gap 76 and deforms the insulatedwires 53 with four bends of 90°. The engagement of the rib 66 with theinsulated wire provides a strain relief means to inhibit the insulatedwires 53 from being pulled from the backbone 51.

Turning to FIG. 7, the backbone cover 52 is shown having rib 66. Thebackbone cover 52 slides over the backbone and the rib 66 abuts andcompresses the insulated wires to provide a strain relief mechanism.FIG. 8 is a side elevation view of the backbone cover 52 having rib 66.

Turning to FIG. 9, the backbone 51 is shown having its second side 64exposed. An end portion 65 of the flat ribbon cable is inserted at afirst side 63 of the backbone 51. The flat ribbon cable is placed ontothe backbone 51 at the first side 63 at an angle transverse to thelength of the backbone 51. The flat cable 65 is folded around thebackbone 51 onto the second side 65 at a first fold 67. A second fold 68is made at an angle in which the end portion 56 of the flat cable isfolded over on itself and redirects the flat ribbon cable in a 90° turnso that the end portion 56 is then directed parallel to the length ofthe backbone 51.

Channels 71 are integrally molded into the second side 64 of thebackbone 51. The conductors 57 of the flat cable 56 are inserted intothe channels 71. The flat cable is retained on the backbone 51 via pins73 which protrude from the sides of the backbone and under which theflat cable 56,65 is positioned. By the positioning of the flat cable56,65 under the pins 73 of the backbone 51 and the folding of the flatcable at first fold 67 and second fold 68, the flat cable becomessecuredly attached to the backbone 51. This assembly of the flat cableterminated onto the backbone is all that is required for the assembly ofthe clockspring itself. The assembled backbone may then be inserted intothe passage 58 of the housing 12. The use of the backbone 51 allows forthe simple termination of the flat cable 56,65 without the need toimmediately attach exterior cables to the flat cable. The presentinvention allows for the subassembly of the rotor cover, housing, insidediameter connector, outside diameter connector and flat cable separatefrom the harnesses to be attached at a final operation. The clockspring10 may then continue to be assembled without having to attach cumbersomeexterior cables and harnesses.

The backbone 51 includes channels 71 which are separated by ribs 75. Agroove 76 is also integrally molded into the backbone 51 and providesfor an area into which the insulated wires may be depressed uponattachment of the backbone cover. Positioning ribs 77 are located at theend of the backbone 51 and are of a sufficient width so that aninsulated wire (not shown) may be press fit between the positioning ribs77. These positioning ribs 77 will also be melted by contact with a heatstake to secure the inserted wires in the channels 71.

FIG. 10 is an end view of a completely assembled backbone 51 havingconductors 57 attached to uninsulated wires 62. Turning to FIG. 11, atop view of a completely assembled backbone 51 is shown having a flatcable 56 with uninsulated conductors 57 protruding from the flat cable56 into channels 71. After a clockspring is completely assembled, theexternal harness 60 will be attached to the clockspring by aligning theindividual insulated wires 53 in the channels 71. The insulated wires 53are inserted between the ribs 75 and positioning ribs 77 and theuninsulated wires 80 are aligned with the conductors 57 of the flatcable 56. The insulated wires are press fit between the positioning ribs77 and are held in place to the backbone 51 therein. The positioningribs 77 are then melted by contact with a heat stake which forms ahomogeneous layer above the insulated wires 53, closing the openingabove the insulated wires 53 adjacent the positioning ribs 77 andsecuring the wires within the channels 71.

In a preferred method of attaching the wires 53 to the conductors 57 ofthe flat cable 56, the uninsulated wires 80 are ultrasonically welded tothe conductors 57. A backbone cover 52 is then slid over the backbone 51to protect the terminated and connected ends of the conductors andwires. The backbone cover 52 includes a rib 66 which abuts the insulatedwires 53 at area 81 and compresses the wire into groove 76 causing theinsulated wire 53 to deform as shown in FIG. 6. Because the engagementof the rib 66 against the wires 53 occurs at the insulated area of thewire 53, a strain relief function is created. The backbone cover 52 issecured to the backbone 51 by any means. In a preferred embodiment, arivet is used to secure the backbone cover. It is anticipated by thisinvention that the specific termination means and method describedherein is only by way of an example and other specific components andmethods are also covered.

Turning to FIG. 12, a side elevation cut-away view taken at line D--D ofFIG. 3 is shown. The clockspring 10 includes the rotor cover 16 andhousing 12. The locking means 40 is shown protruding from a clockspring10 assembled within a steering wheel housing 85 and a steering columnhousing 86. The locking means 40 has pull tab 46 protrudingperpendicularly from the housing 12 at a point 87 along the sidewall 14of the housing 12 which is specifically oriented to be below thesteering wheel housing 85 and above the steering column housing 86. Uponassembly of the clockspring within these housings 85,86, a gap 90 isformed through which the pull tab 46 protrudes. The pull tab 46 isintegrally connected to the latching body 41 which is seated withinchannel 42. A stop head 45 is integral to the latching body 41 protrudesbeyond the plane of the rotor cover 16. A stop wing 48 engages the stophead 45 and limits the rotor cover 16 from rotating beyond 350°.

Turning to FIG. 13, the automatic unlocking means 30 is shown. Theunlocking means 30 is shown in its undepressed locked position. Thedrawing shows a cut-away, side elevation view of FIG. 3 taken at lineC--C. A button 35 includes a sliding surface 31 and a detente 36. Thebutton 35 is positioned adjacent to the bottom opening 22 of the rotorcover 16 and within cell 32. U-shaped spring member 38 forces the button35 towards the center 39 of the clockspring 10. The spring member 38abuts tab 91 which retains the spring member 38 and button 35 withincell 32. In its locked position, the detente 36 is forced into a recess37 of the housing 12. The sides of the detente 36 engage the inner wallsof the recess 37 and prevent the rotation of the rotor cover 16 inassociation with the housing 12. In a preferred embodiment, the detente36 includes beveled edges engaging correspondingly tapered walls of therecess 37. The beveled edges ensure that the detente 36 will notdisengage from the recess 37. Further, the recess is widely spacedallowing gaps on either side of the detente 36 so that even uponengagement of the detente 36 within recess 37, minor rotation of 10° (5°in each direction) of the rotor cover 16 is allowed.

Turning to FIG. 14, the button 35 is shown in its depressed and unlockedposition. Upon assembly of the clockspring 10 into a steering assembly,a steering wheel section (not shown) will be inserted into the topopening 21 of the rotor cover 16 in the direction of arrow 90 and itwill abut the sliding surface 31 of the button 35. The further insertionof the steering wheel within the clockspring 10 will cause the button 35to move away from the center 39 and the steering wheel section willslide along the front surface 34 of the button 35, depressing the springmember 38 and moving the button into cell 32 and detente 36 out ofrecess 37 of the housing 12. The removal of detente 36 from recess 37allows the rotor cover 16 to rotate freely about the housing 12. Thus,the assembly of the clockspring to a steering assembly engages theautomatic unlocking means 31 allowing it to rotate freely.

Turning to FIG. 15, a top view of an alternative embodiment of thepresent invention is shown. Rotor cover 116 includes aperture 120 andhas formed thereon a first connector location 150. An additional featureof a nonreplaceable lock 100 includes gripping member 101, securementtab 102 and stop tab 103. In a preferred embodiment, the nonreplaceablelock 100 is comprised of a polymer material such as minlon or hytrel.Securement tab 102 is inserted into insertion slot 105 which is formedas part of the rotor cover 116. This alternative embodiment of aclockspring includes a housing cover 120 which is stationary. Thehousing cover 120 includes lip 121 and projection 122. Upon rotation ofthe rotor cover 116, the nonreplaceable lock 100 is attached to therotor cover 116 and rotates with the rotor cover 116. Rotation in afirst direction or the counter-clockwise direction approximately 90°from the position shown in FIG. 15 causes stop tab 103 to abut lip 121of housing cover 120. This abutment prohibits the rotor cover 116 fromrotating any further in the counter-clockwise direction. Rotation of therotor cover 116 in a second direction or the clockwise direction,approximately 90° from its position as shown in FIG. 15, causes stop tab103 to abut projection 122. The abutment of stop tab 103 againstprojection 122 prohibits the rotor cover 116 from rotating any furtherin the clockwise direction.

Similar to the locking means 40, as shown in FIG. 12, the nonreplaceablelock 100 provides a temporary locking means which allows limitedrotation of the rotor cover 116 to allow for necessary movement of theclockspring for final installation to a steering assembly whilepreventing the clockspring from becoming uncentered. In a preferredembodiment, the lip 121 and projection 122 are oriented so thatapproximately 180° of rotation of the rotor cover 116 is allowed so thatfinal assembly of the clockspring to a steering column may be easilyaccomplished while insuring that the clockspring will remain centered.In a preferred embodiment, other locks may be present which prohibitrotation of the clockspring prior to initial assembly but aredeactivated upon attachment of the clockspring to the steering column(see U.S. Pat. No. 5,171,157), leaving the nonreplaceable lock to limitrotation following attachment of the clockspring to the steering column,but allowing for additional adjustments to the steering column duringfinal assembly of the steering assembly. After final assembly of theclockspring to a steering assembly, the nonreplaceable lock 100 can beeasily removed from the clockspring by grasping gripping member 101 andremoving the nonreplaceble lock 100. The gripping member 101 will becomeseparated from the securement tab 102 and cannot be replaced thereto.

Turning to FIG. 16, a cut-away view of FIG. 15 taken at line E--E isshown. The nonreplaceable lock 100 is mounted on rotor cover 116.Securement tab 102 is inserted in slot 105 and is retained therein via afriction fit. Slot 105 includes angled wall 105a which causes thesecurement tab 102 to compress as it is fully inserted within the slot105. Stop tab 103 protrudes from the nonreplaceable lock 100 at theopposite side from the securement tab 102. The stop tab 103 is parallelto sidewall 114 of housing 120. The housing 120 and the rotor cover 116form chamber 118 in which the conductor cable of the clockspringresides.

The channel 105 is integrally molded with the rotor cover 116 andincludes a ramp 106. The ramp allows for easy insertion of the insertiontab 102 into the slot 105. The nonreplaceable lock 100 also includesknob 108 which is frictionally fit in a crevice 109 of the rotor cover116. The knob 108 provides for a second point of attachment of thenonreplaceable lock 100 so that it does not flap around or rock back andforth on the axis of the securement tab 102. It should be noted,however, that the friction fit of the securement tab 102 in slot 105 ismuch greater than the friction fit of the nub 108 in crevice 109.

Upon delivery of a clockspring having the nonreplaceable lock 100mounted thereon, the clockspring may be assembled to a steeringassembly. Such final assembly may require rotation of the rotor housing116. As discussed above, in a preferred embodiment 180° of rotation isallowed by the nonreplaceable lock 100. During this rotation, thehousing 120 is stationary while the rotor cover 116 rotates. Thisrotation is also transferred to the nonreplaceable lock 100 and the stoptab 103 will move along wall 114 in the direction of the rotation. Thestop tab 103 will abut lip 121 at one limit of rotation and protrusion122 at the other limit of rotation. Once the clockspring is completelyassembled to the steering assembly, the nonreplaceable lock 100 may thenbe removed. By grasping the gripping member 101 of the nonreplaceablelock 100, the nonreplaceable lock 100 may be rotated upwardly and towardthe center of the clockspring in direction of arrow 110. This is causedby removing nub 108 from crevice 109. The securement tab 102 has aindentation 111 which forms a pivot point 113. The nonreplaceable lock100 will pivot at pivot point 113 and be rocked towards aperture 120 ofthe clockspring so that the gripping member 101 is moved 90° from itsinitial position shown in FIG. 16 so that it is perpendicular to the topof the rotor cover 116. Once rotated in this position, thenonreplaceable lock 100 may be removed from the clockspring by tearingthe polymer material at pivot point 113, leaving the base portion ofsecurement member 102 in the slot 105. As the securement tab 102 hasbeen separated into two sections, the nonreplaceable lock 100 can not bereplaced on the clockspring. This method of having the nonreplaceablelock 100 on the top surface of the clockspring easily allows aninspector to see that the nonreplaceable lock 100 has been removed. Thisshould signal that the assembly of the clockspring to the steeringassembly has been completed. Removal of the nonreplaceable lock 100before initial assembly of the clockspring to a steering column willalert inspectors that the clockspring may be uncentered and should bediscarded.

The description above has been offered for illustrative purposes only,and it is not intended to limit the scope of the invention of thisapplication which is defined in the following claims.

What is claimed is:
 1. A clockspring connector comprising:a housingdefining a chamber; a rotor cover attached to said housing; a flatconductor cable coiled within said chamber having a first and a secondend; said first end attached to said first rotor cover; said second endattached to said housing; and a nonreplaceable locking means allowinglimited rotation of the rotor cover less than 180 degrees, having asecurement tab which is severed during removal of the nonreplaceablelocking means so as to remain within a slot of the clockspringconnector.
 2. The clockspring interconnector of claim 1 wherein:saidnonreplaceable locking means is attached to said rotor cover.
 3. Theclockspring interconnector of claim 2 comprising:a lip protruding fromsaid housing; a projection protruding from said housing a specifieddistance from said lip; and a stop tab attached to said nonreplaceablelocking means which will abut said lip when rotated in a first directionand said projection when rotated in a second direction.
 4. Theclockspring interconnector of claim 3 comprising:a gripping memberattached to said nonreplaceable locking means.
 5. The clockspringinterconnector of claim 4 wherein said gripping member, said stop taband said securement tab are integrally connected.
 6. The clockspringinterconnector of claim 1 wherein said securement tab includes a meansfor separation of said securement tab from said nonreplaceable lockingmeans.
 7. The clockspring interconnector of claim 6 wherein said meansfor separating includes a indentation for allowing the rippingseparation of the nonreplaceable locking means from said securement tab.8. The clockspring interconnector of claim 1 wherein removal of saidnonreplaceable locking means allows said rotor cover to rotate more than180°.